C. Repair Procedure

Fuel Seepage (Replacement of Fuel Pump Lock Ring & Fuel Pump Seal)

CAUTION:
^ The following Repair Procedure must be performed in a well ventilated area, away from direct sunlight, flames, or sparks.

^ Gasoline is very flammable, use extreme caution when working near or around gasoline.

^ Appropriate hand and eye protection must be worn when working with gasoline.





1. Disconnect the gray and black connectors.





2. To prevent damage to the connector/wires, tape the female side of the gray connector to the vehicle body and tuck the male side of both the black connector and gray connector inside the floor carpet.

3. To release the fuel pressure, start the engine and wait until it stalls, then crank the engine for an additional five (5) seconds.

4. Turn ignition switch to "OFF" position.

5. Disconnect the negative side battery cable.





6. Clean all debris from the top of the fuel tank using compressed air.





7. Wipe the area clean with a clean cloth.

NOTE:
It is important to clean the area thoroughly. A tool will be used to measure the gap between the bottom of the fuel pump lock ring and fuel tank.





8. Remove the green fuel line retainer clip by gently expanding it.

CAUTION:
To prevent clip breakage, do not over-expand the clip.





9. Cover the end of the fuel line with a clean cloth and detach it from the fuel pump coupler by pulling outward on the fuel line.

CAUTION:
Detach the fuel line slowly, some fuel pressure may still exist.





10. After removing the fuel line, make sure the blue plastic cage is not lost.

11. Wrap the fuel line with a clean cloth and tuck it away from the main opening.





12. Check the black number molded into the top of the lock ring. This identifies if the correct lock ring is installed.

^ If the number "1" or "2" is found, proceed to "B. REPAIR PROCEDURE (Replacement of Fuel Pump Lock Ring & Fuel Pump Seal Inspection)."

^ If the number "3" or "4" is found, proceed to the next step.





13. Check for the presence of a black arrow molded into the top edge of the lock ring.

^ If the arrow is present, proceed to the next step.

^ If the arrow is not present, proceed to "B. REPAIR PROCEDURE (Replacement of Fuel Pump Lock Ring & Fuel Pump Seal Inspection)."

14. Lift the vehicle on the hoist.





15. Locate the white label attached to the exterior of the fuel tank (on passenger side of vehicle).

NOTE:
If there is no label on the fuel tank, note the production date stamping on the bottom of the tank.

16. Record the production date printed on the label or bottom of fuel tank.

17. Lower the vehicle and proceed to the next step.

18. Using the production date of the fuel tank, inspect the position of the lock ring arrow.

NOTE:
There are two (2) correct positions for the lock ring arrow depending on the fuel tank production date.





^ Fuel tank date on or before 03/02/03: Lock ring arrow should be between 9:00 & 12:00.





^ Fuel tank date on or after 03/03/03: Lock ring arrow should be between 12:00 & 3:00.

NOTE:
The 12:00 location is oriented at the two (2) molded ribs of the fuel tank.

19. Determine the position of the lock ring arrow.

^ If the lock ring arrow position is incorrect, proceed to the next step.

^ If the lock ring arrow position is correct, proceed to Step 21.





20. Mount the SST (Fuel Pump Ring Removal Wrench) onto the lock ring and tighten in a clockwise direction until the arrow is in the correct position. Remove the SST and proceed to the next step.





21. Using the SST (Fuel Pump Lock Ring Gauge) as a "go/no go" gauge insert the thinnest side (.5 mm) between the bottom of the lock ring and the fuel tank.

NOTE:
Only the very tip of the SST is .5 mm. This is the only portion of the SST that needs to be inserted between the lock ring and fuel tank.





22. Check all twelve (12) points around the lock ring (in between each lock ring rib).

^ If the SST can be inserted into all twelve (12) points of the lock ring, proceed to the next step.

^ If the SST cannot be inserted into all twelve (12) points of the lock ring, the fuel tank must be replaced. DO NOT disturb the condition of the lock ring. Contact the Mazda Technical Assistance Hotline for authorization of the fuel tank. Proceed to "D. REPAIR PROCEDURE (Replacement of Fuel Tank, Fuel Pump Lock Ring & Fuel Pump Seal)."

CAUTION:
To prevent fuel odor inside the vehicle, reconnect the fuel line to the fuel pump coupler and reinstall the access cover until the new fuel tank arrives.





23. Mount the SST (Fuel Pump Ring Removal Wrench) onto the lock ring and remove the lock ring in a counterclockwise direction.

24. Discard the lock ring.

25. Remove the SST (Fuel Pump Position Retainer).





26. Remove the fuel pump by grasping the fuel pump housing and lifting upward. Place the pump in a clean container.

CAUTION:
^ Some amount of fuel is inside of the fuel pump, while removing the fuel pump, pour the fuel back into the fuel tank being careful not to spill the fuel.

^ When lifting the fuel pump out of the fuel tank, make sure that the float is not damaged or bent.





27. Remove and discard the fuel pump seal.





28. Install a new fuel pump seal.

NOTE:
Make sure that the seal is installed "level" onto the fuel tank and that no portion of the seal is tucked inside the fuel tank. Use a mirror to aid in the inspection.

29. Obtain the fuel pump.





30. Locate the white molded arrow on top of the fuel pump.





31. Hold the fuel pump above the fuel tank opening and visually align the arrow on the fuel pump between the molded ribs on the fuel tank.





32. Tilt the fuel pump so that the float enters the fuel tank.





33. After the float enters the fuel tank, straighten up the fuel pump to an upward position and slowly insert the fuel pump into the fuel tank.

CAUTION:
Make sure that the fuel pump seal does not become "rolled" or damaged.





34. During the fuel pump installation, the fuel pump may have moved slightly. Ensure that the white colored molded arrow on top of the fuel pump is centered between the molded ribs on the fuel tank. If not, grasp the top of the fuel pump and move it until the arrow is centered.

35. Obtain the SST (Fuel Pump Position Retainer).

NOTE:
Prior to using the SST for the first time, the securing bolt (M6) may be difficult to thread onto the SST by hand. If so, "clean" the threads by partially threading the bolt on by hand, then use a 10 mm wrench to further clean the threads.





36. Carefully lower the SST (Fuel Pump Position Retainer) onto the top of the fuel pump and insert the SST "leg" into the square shape slot.

NOTE:
^ The installation of the SST keeps the fuel pump from popping upward (the fuel pump is under spring pressure) and/or the fuel pump seal from moving when the lock ring is removed. Ignore the dates stamped on the top surface of the SST.





37. Secure the SST by inserting the bolt through the square shape slot, threading it onto the SST, then snug the bolt down.





38. Using a mirror and a flashlight, inspect the complete circumference of the fuel pump seal for a "rolled" seal condition.

NOTE:
The fuel pump seal is between the fuel pump and the top of the fuel tank.

^ If the seal is not rolled, proceed to Step 42.

^ If the seal is rolled, proceed to the next step.

39. Grasp the fuel pump housing and lift it up approx. 2".

40. Using the tip of your finger, correct the rolled portion of the seal.





41. Reinsert the fuel pump and repeat Step 38.

NOTE:
Ensure the white molded arrow on top of the fuel pump has not moved and is centered between the molded ribs on the fuel tank. If not, grasp the top of the fuel pump and move it until the arrow is centered.





42. Obtain a new lock ring and align the molded arrow on the lock ring with the machined line (Lock Ring Start) on the SST.

NOTE:
The arrow on the lock ring represents the starting thread.

43. Lower the lock ring straight down until the threads just contact the fuel tank threads. At this time the lock ring should be laying flat on the fuel tank threads.





44. Using both hands, push down on the lock ring and turn it clockwise approx. 1" until the threads engage, then release the lock ring. Push downward on the lock ring on the opposite side of the black molded arrow. A "click" noise should be heard just as the threads "catch". Once the threads catch, proceed to the next step.





45. Install the SST onto the lock ring and tighten in a clockwise direction for 3/4 of a turn.

NOTE:
^ When the lock ring is being tightened, it may feel slightly rough. If excessive effort is required to turn the lock ring, the lock ring threads may not be correctly fitted onto the fuel tank threads. If this is the case, remove the lock ring and repeat Steps 42-45.

^ It is not necessary to replace the lock ring again if steps 42-45 are repeated.





46. Visually inspect for uneven gap(s) between the top inner edge of the lock ring and the top of the fuel pump

^ If no uneven gaps are noted, proceed to the next step.

^ If any uneven gaps are present, remove the lock ring and repeat Steps 42-46.

NOTE:
It is not necessary to replace the lock ring again if Steps 42-46 are repeated.

47. Install a 19 mm socket onto the SST and tighten the lock ring until the lock ring arrow is in the correct position.

NOTE:
The lock ring can be rotated a maximum of 1 3/4 turns.

48. To ensure that the lock ring has reached minimum torque, mount a "click" type torque wrench on the top of the SST and apply 50 Nm (36.8 ft. lbf.) to the lock ring. The torque wrench should "click" and the lock ring should not rotate beyond the correct position.

NOTE:
Ensure the white molded arrow on top of the fuel pump has not moved and is still centered between the molded ribs on the fuel tank. If the arrow is not centered, the fuel gauge may read incorrectly.

^ If the torque wrench "clicks", proceed to the next step.

^ If the torque wrench does not "click", the fuel tank may need to be replaced. At this time, DO NOT disturb the condition of the lock ring. Contact Mazda Technical Assistance Hotline for authorization of the fuel tank. Proceed to "D. REPAIR PROCEDURE (Replacement of Fuel Tank, Fuel Pump Lock Ring & Fuel Pump Seal)" once the new fuel tank arrives.

CAUTION:
To prevent fuel odor inside the vehicle, reconnect the fuel line to the fuel pump coupler and reinstall the access cover until the new fuel tank arrives.





49. Remove both SSTs (Fuel Pump Ring Removal Wrench and Fuel Pump Position Retainer).





50. Using the SST (Fuel Pump Lock Ring Gauge) as a "go/no go" gauge, insert the thinnest side (.5 mm) between the bottom of the lock ring and the fuel tank.

NOTE:
Only the very tip of the SST is .5 mm. This is the only portion of the SST that needs to be inserted between the lock ring and fuel tank.





51. Check all twelve (12) points around the lock ring (in between each lock ring rib).

^ If the SST can be inserted into all twelve (12) points of the lock ring, proceed to the next step.

^ If the SST cannot be inserted into all twelve (12) points of the lock ring, the fuel tank must be replaced. DO NOT disturb the condition of the lock ring. Contact Mazda Technical Assistance Hotline for authorization of the fuel tank. Proceed to "D. REPAIR PROCEDURE (Replacement of Fuel Tank, Fuel Pump Lock Ring & Fuel Pump Seal)" once the new fuel tank arrives.

CAUTION:
To prevent fuel odor inside the vehicle, reconnect the fuel line to the fuel pump coupler and reinstall the access cover until the new fuel tank arrives.





52. Using the SST (Fuel Pump Lock Ring Gauge) attempt to insert the thickest side (6.0 mm) between the bottom of the lock ring and the fuel tank.





53. Check all twelve (12) points around the lock ring (in between each lock ring rib).

^ If the SST can be inserted into any of the twelve (12) points of the lock ring, install SST (Fuel Pump Position Retainer) and repeat Steps 42-53.

^ If the SST cannot be inserted into any of the twelve (12) points of the lock ring, proceed to the next step.





54. The plastic cage may have fallen off during removal of the fuel line. Reinstall the cage by first aligning the grooves on the cage to the grooves on the fuel line, then push the cage inward.

NOTE:
There are four (4) grooves on the fuel line. Make sure to use the smaller grooves.





55. Reinstall the green fuel line retainer clip.

NOTE:
^ Position the clip so the tab is pointing towards the fuel line hose. Align the lock tab to the fuel line openings and install the retainer clip.

56. Reinsert the fuel line into the fuel pump coupler by snapping it into the coupler until a "click" noise is heard.

NOTE:
To ensure that the fuel line is fully secure into the fuel pump coupler, slightly tug on the fuel line.





57. Reconnect the gray and black connectors.

58. Reconnect the negative battery cable.

59. Crank the engine until it starts and ensure there is no fuel leakage at the fuel line.

60. Turn the engine off.

61. Turn the ignition to the "ON" position and check the fuel gauge.

^ If the fuel gauge reads between 1/4 and 1/2, proceed to Step 63.

^ If the fuel gauge reads less than 1/4, make a note of the amount and proceed to the next step.





62. Add the necessary amount of fuel to bring the fuel gauge between 1/4 to 1/2.

NOTE:
The fuel level must not be more than 1/2 to run the WDS EVAP test.

63. Perform EVAP test using WDS.

^ If the vehicle passes the WDS EVAP test, proceed to the next step.

^ If the vehicle fails the WDS EVAP test, repeat "C. REPAIR PROCEDURE (Replacement of Fuel Pump Lock Ring & Fuel Pump Seal)." It is not necessary to replace the fuel pump lock ring or fuel pump seal again.

64. Reinstall the fuel pump access cover.

65. Reinstall the seat bottom.

NOTE:
Prior to installing the seat bottom, feed all seat belts through bottom of seat cushion.

66. Reprogram all of the customer's preset radio stations.

67. Proceed to "E. AUTHORIZED MODIFICATION LABEL INSTALLATION."

68. Return the vehicle to the customer.